Field-replaceable composite roll system for corona treatment

ABSTRACT

A Field-Replaceable Composite Roll system (FRCR) consists of a complex composite cover and a unique mechanical mounting system, configured to allow the retrofit of existing silicone sleeved rolls, as well as manufacture new rolls, at substantially lower costs. The system of the present invention can be used for retrofitting existing dead-shaft or live-shaft rolls previously manufactured to use silicone sleeves, as well as fabricating new rolls in conjunction with the patented WINERTIA® brand tubing or conventional thin-walled tubing. The exemplary embodiment of the composite cover is fabricated of a filament wound tube bound together via a resin or the like having dielectric properties, the tube forming inner and outer walls, the inner wall coated with a conductive layer for receiving and conducting an electric current, the outer wall coated with a wear resistant layer (illustrated as ceramic coating), followed by a sealant layer. The composite cover is configured to slide over and envelope a roller body, and be anchored in place via mechanical mount formed of first and second expansion rings and associated compression bases.

REFERENCE TO EARLIER FILED APPLICATIONS

[0001] The present invention is a continuation-in-part of provisionalpatent application having serial No. 60/294,530, docket numberENCORE02/01, filed May 30, 2001.

FIELD OF THE INVENTION

[0002] The present invention relates to dielectric rollers for use incorona treatment applications, and in particular to a Field-ReplaceableComposite Roll System for replacing a worn out dielectric roller sleeveor cover in the field, without the necessity of special procedures ortools. Present state-of-the-art in field replaceable rolls only includethe use specially configured silicone sleeves comprising an elastic tubemade of a silicone rubber compound. Performance compromises with thesilicone sleeve include very poor resistance to abrasion and knife cut,short life, difficult replacement process, and a limitation in useablesizes. Other rollers require factory rebuild or simple replacement.

[0003] The preferred embodiment of the present invention contemplates aField-Replaceable Composite Roll system (FRCR) consists of a complexcomposite cover and a unique mechanical mounting system, configured toallow the retrofit of existing silicone sleeved rolls, as well asmanufacture new rolls, at substantially lower costs. Details for thedesign and manufacturing of the FRCR are described in this document tocover: (1) retrofitting existing dead-shaft or live-shaft rollspreviously manufactured to use silicone sleeves, (2) designing new rollsusing the patented WINERTIA® brand tubing, and (3) designing new rollsusing conventional thin-walled tubing.

[0004] The exemplary embodiment of the composite cover is fabricated ofa filament wound tube bound together via a resin or the like havingdielectric properties, the tube forming inner and outer walls, the innerwall coated with a conductive layer for receiving and conducting anelectric current, the outer wall coated with a wear resistant layer(illustrated as ceramic coating), followed by a sealant layer.

[0005] The composite cover is configured to slide over and envelope aroller body, and be anchored in place via mechanical mount formed offirst and second expansion rings and associated compression bases.

BACKGROUND AND PRIOR ART

[0006] Dielectric rollers have been utilized for years in conjunctionwith corona treatment stations and the like, utilizing a variety ofmaterials, including resin, ceramic, glass, silicone, and the like.Generally, the roller is covered with a dielectric compound tofacilitate proper operation in the capacity of a roller electrode. Inuse, the corona field and resulting electrical discharge of currentresults in the emission of ozone and the creation of heat. The currentemissions, ozone, and heat causes pitting and cracking of the treatmentsurface of the rollers over time, and eventually these rollers have tobe replaced or repaired. Typically, the rollers must be removed from thetreater stations, resulting in expensive machine down time. Siliconesleeves have been used as a protective, replaceable dielectric layer,which sleeves are replaceable in the field, but the sleeves areexpensive, do not last long as other materials, and they are easilydamaged.

[0007] Patents of relevance to the present system include:

[0008] U.S. Pat. No. 5,169,450 teaches a “Corona Treatment RollerElectrode” wherein there is taught a “self-supporting” tubular bodyhaving an inner conductive layer and outer dielectric layer, the tubularbody supported via end plugs (12,13) at each of its ends. Thus, theinterior of the '450 roller is hollow, the tube not configured to slipover existing rollers to provide an easy renewal of same, but rather itcontemplates a specialized roller application utilizing special end capsnot apparently compatible with third party roller designs.

[0009] EPO Patent 0 274 043 B1 teaches a roll electrode comprising atubular electrode layer (4) having an insulated layer (5) apparentlycomprising a tube which is slipped thereover (FIGS. 3-5). Nonetheless,the patent does not appear to teach the concept of a replacement sleeveconfigured to slip over the body of an existing roller, coupled with amounting mechanism configured to engage and retrofit existing rollers,as well as a specialized roller system for providing relatively easilyaccomplished refurbishing of electrode rollers on site.

GENERAL SUMMARY DISCUSSION OF THE INVENTION

[0010] Unlike the prior art, the present invention provides an effectivesystem for on site replacement of worn portions of an electrode rolleras used in corona field generator treatment stations which is quick,effective, and requires little training and no specialized tools ortechniques.

[0011] The preferred embodiment of the present invention contemplates aField-Replaceable Composite Roll (FRCR) system wherein there is provideda complex composite cover and a unique mechanical mounting system. Thenovelty in this invention is that is can be used to both retrofitexisting silicone sleeved rolls, as well as providing off-the-shelf newrolls for use in new systems, at substantially lower costs than existingsystems.

[0012] Details of the fabrication and operation of the FRCR aredescribed in the present text to cover: 1) retrofitting existingdead-shaft or live-shaft rolls previously manufactured to use siliconesleeves, 2) providing new rolls utilizing the third party WINERTIAtubing, and 3) providing a new roller system utilizing conventional thinwalled tubing.

[0013] The tube of the present invention configured to fit over existingrollers comprises a sleeve that consists of a filament wound tube toserve as a dielectric for corona treating, an innermost conductive layerfor draining electrical current to earth ground, an outermost wearresistant layer constructed of ceramic, and a sealant coating tomoisture proof the ceramic layer. Further, the wear resistant layer canbe of a color with a sharp contrast to that of the filament wound tubeto indicate wear.

[0014] A Mechanical Mounting System of the present invention formounting the tube in place includes a preferred embodiment consisting ofan Expansion Ring and a Compression Base. The Expansion Ring is used toapply an expansive and radially distributed force of friction uniformlyon the Inside Diameter of the Complex Composite Cover to secure itwithout an invasive means. The Compression Base is used to apply acompressive and radially distributed force of friction uniformly on theOutside Diameter of a roll shaft to establish a concentric mount withoutan invasive means. Further, the Expansion Ring and the Compression Baseutilize matching taper surfaces to convert perpendicular motion createdby fasteners pulling the two pieces together to radial motion, whichultimately creates the force of friction such as described.

[0015] The Mechanical Mounting System can be used to retrofit anyexisting rollers, which were previously covered with a rubber, glass,epoxy, or ceramic compound, including the field-replaceable siliconetubing or sleeve. Further, the retrofit does not require establishing anew connection to earth ground as the existing ground connection isautomatically extended to the conductive layer of the Complex CompositeCover.

[0016] Said Mechanical Mounting System and Complex Composite Cover canbe quickly installed in the field without any special tooling or heavylabor. No force is required to install the system other than the normalforce that is used to tighten small fasteners. Further, concentricity isautomatically achieved between the roll to be retrofit and the newComplex Composite Cover.

[0017] An alternative embodiment of the present invention consists of anAdapter Ring and Complex Composite Cover can be combined with thepatented Winertia® Idler Roll Technology to design new rolls for OEM'sto have both technical innovation and lower production costs. TheAdapter Ring requires simple machining operation to achieve thenecessary dimensions for the design to work. Further, the Adapter Ringcan be mass produced such as casting to further lower production cost.Innovative and cost cutting features include (1) quick fieldinstallation requiring no special tool (2) no machining required to thetube (3) enhanced cooling to lengthen the life of the dielectric (4)precise placement for thread inserts and installation fasteners by usingthe inclusive slots intended for balancing (5) universally adaptable forlive or dead shaft designs (6) inclusive webbing can replace sensingpoints for the purpose of detecting roll motion (7) recommended recessin ends allows ready placement for the Adapter Ring.

[0018] Said Adapter Ring and Complex Composite Cover can be included inall conventional roll designs using standard ‘Drawn Over Mandrel’ tubingand achieve both technical innovation and low production costs asdescribed above.

[0019] It is therefore an object of the present invention to provide anon-site composite roll conversion/retrofit system to facilitate quickreplacement of worn dielectric roller covers.

[0020] It is another object to provide a dielectric roller system whichmay be incorporated into existing roller designs, or as a substitute forexisting rollers in new units, wherein personnel may change out wornportions of said rollers on site without specialized tools orinstruction.

[0021] Lastly, it is an object of the present invention to provide adielectric roller system for corona treatment which costs less, iseasier to maintain, and performs as well as or better than prior artsystems.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022]FIG. 1A is a side, cross-sectional view of the core forming thetube of the present invention.

[0023]FIG. 1B is and end view of the tube of FIG. 1A.

[0024]FIG. 1C is a side, close-up view of the invention of FIG. 1A,illustrating in detail the layers forming the tube of the presentinvention.

[0025]FIG. 2 is a side, partially cut-away view of the tube of FIG. 1A,illustrating the visual inspection of the interior of the tube.

[0026]FIG. 3 is a side, partially cut-away view of the tube core of FIG.1, illustrating the application of a conductive layer to the interior ofthe tube core.

[0027]FIG. 4 is a side view of the first step of fabricating the tubecore of FIG. 1, illustrating the application of a carbon veil strip to amandrel mounted to a winder.

[0028]FIG. 5 illustrates the application of a ceramic layer to the outersurface of the tube core of FIG. 1.

[0029]FIG. 6 is an isometric view of the application of a sealant to thetube core of FIG. 1 using a vacuum pressure impregnation apparatus.

[0030]FIG. 7 is an end view of a first of two expansion rings utilizedto support the first and second ends of the tube of FIG. 1,respectively.

[0031]FIG. 8A is an isometric view of the compression base forretrofitting a dead shaft roll.

[0032]FIG. 8B is an end view of the compression base of FIG. 8A. FIG. 9Ais an isometric view of an alternative compression base for retrofittinga live shaft roll.

[0033]FIG. 9B is an end view of the compression base of FIG. 9A. FIG.10A is a side, cross-sectional view of the mechanical mounting system ofFIG. 10A is a side, cross-sectional view of the mechanical mountingsystem to retrofit existing rolls.

[0034]FIG. 10B is an end view of the invention of FIG. 10A.

[0035]FIG. 11A is a side, partially cut-away view illustrating theretrofit of a previously covered roll with the mechanical mountingsystem of the present invention.

[0036]FIG. 11B is an isometric view of the invention of FIG. 11A. FIG.12 is a side, cut-away, cross-sectional view of the composite cover forfield replacement of the present invention.

[0037]FIG. 13 is a side, isometric view of an alternative fieldreplaceable composite roll system for OEM applications utilizingWINERTIA technology.

[0038]FIG. 14 is a side view of an adapter ring as used in the presentinvention for use in the present invention.

[0039]FIG. 15A illustrates an isometric view of an embodiment of thepresent invention wherein there is provided the mounting of the tubesleeve over an OEM roll.

[0040]FIG. 15B is a side, partially cross-sectional, partially cutawayview of the invention of FIG. 15A.

DETAILED DESCRIPTION OF THE INVENTION

[0041] Referring to FIGS. 1A-1C of the drawings, the preferredembodiment of the present invention comprises a tube T formed from acore member 8 having inner 1 and outer 3 walls and inner 2 and outer 4diameters, respectfully, a thickness 5 therebetween, and first 6 andsecond 7 ends. As shown, the core member 8 is formed of compositematerials having appropriate dielectric properties, a conductive layer 9lining inner wall 2 of the core member, a wear resistant ceramic layer10 applied over the outer wall 3 of the core member, and a sealant coat11 encapsulating the ceramic layer, so as to seal any pores or the likeformed in said ceramic layer. FIGS. 1A-1C show the basic construction ofthe tube, which can be manufactured to have any inside diameter (ID),outside diameter (OD) and length (Lg).

The Filament Wound Tube

[0042] Companies who specialize in filament winding of composite tubesfor electrical applications can be used to manufacture the core member8, which preferably is comprised of a filament wound tube. Accordingly,“core member” will refer to the filament wound tube, while “tube T” willrefer to the core member which has been treated to provide an innerconductive layer, an outer ceramic coating, and a sealant. The coremember serves as a mechanical body and a dielectric in the generation ofcorona. Corona generation by high voltage electricity is a process inwhich an electric field of thousands of volts is generated across adielectric to create a sustainable electrical discharge to earth ground.

[0043] A generic filament wound tube designed to function as a coronatreat roll (and core member in the present invention) must possess theproper properties including corona resistance, tensile strength,torsional strength, modulus of elasticity, dielectric strength,dielectric constant, volume resistivity, surface resistivity, powerfactor rating, electrical impulse rating, thermal dissipation factors,and temperature ratings. Specifically, a suitable epoxide system such asthe ‘cyclo-aliphatic’ resin can be selectively formulated throughsuccessive and destructive electrical testings to optimize the desirablecharacteristics.

[0044] Invariably, all filament wound tube manufacturers haveproprietary processes that are used to manufacture composite tubes fordifferent segments of the market. In selecting a qualified manufacturer,the primary factors should include abilities to finish grind a preciseand uniform wall thickness (concentricity), maintain the winding or hoopangles to achieve the proper resin to glass ratio, consistent wetting ofthe glass strands, thermal cure the tube in an oven equipped withrotisseries, and qualify a process to produce low to zero percentporosity.

[0045] Further, referring to FIG. 2, a visual inspection should beperformed on each tube by shining a light source directed out ward frominside the tube to locate any air void that formed as a result ofunwetted glass strands, poor porosity, etc. Tubes that show distinctopaque areas 14 of lines and spots, which may be detected by observationof the outside of the tube from the light source 13 within the tube, arestrong suspects of being defective and should be rejected.

The Conductive Layer

[0046] Continuing with FIGS. 1A-1C and FIG. 3, the inner wall of thecore member 8 is coated with a conductive layer for the purpose ofdraining electrical current safely to earth ground. This separateconductive layer 9 should adhere intimately with the inner wall 1 of thecore member 8 forming the tube T and leave practically no air gap. Airgaps of any appreciable size and quantity could produce unwanted coronaand possibly lead to localize heating and premature failures of thedielectric material forming the core member.

[0047] The simplest approach to fabricate the conductive layer is to‘paint’ the inner wall of the core member with a special liquid via afoam applicator 16 or the like. This special liquid(s) existscommercially in the form of an air dry, conductive paint. Multiple coatsthat are a few mils in thickness will be needed to ensure completecoverage. Since conductive paints are available in several grades, it isimperative that a proper grade be selected based on its ability toadhere to fiberglass, and a surface resistivity rating equal to or lessthan 0.03 ohm/sq. in.

[0048] When applied directly to the inside surface of the tube, the lowviscosity of the paint can be an advantage since it allows the paint tobe worked into the uneven (on a microscopic scale) surface of the tube.In practice, this process is difficult and tiring when done manuallysince the applicator has to be placed on the end of a long pole andextended a few feet to reach the mid portions of the tube. Furthermore,the proven vacuum-pressure-impregnation (VPI) process must be carriedout to minimize air entrapment.

[0049] Another viable approach to construct the conductive layer is toincorporate a layer of conductive material to form the inner wall of thecore member during the construction of the core member, such asutilizing a suitable carbon veil. The veil, available in strip form, isplaced by hand in a single layer 20 of conductive carbon strip spirally(via motor 23 rotating a mandrel 21) and temporarily held in place withtape 22. Neither overlapping of the carbon veil strip nor allowing anydiscernible amount of gap between 24 adjacent strips is acceptable.Doing so will produce an uneven dielectric wall thickness resulting inpoor and inconsistent treat.

[0050] Once the carbon strip is tightly wrapped around the mandrel, thefilament winding process is started right on top of the carbon veil tofabricate a core member of fiber glass and resin, utilizing standardfilament winding techniques. Wetout of the veil with the same resin mixthat is used for filament winding might be required to ensure goodbonding. As compared with conductive paint, a composite coverconstructed with carbon veil will have a strong and integral conductivelayer that is highly resistant to any damage during handling. However,the integral carbon veil does pose some disadvantages including makinginspection by a light virtually impossible since the black carbon blocksthe light. Production can become an issue with the difficulty in handlaying the carbon strips, and extra work is needed to thoroughly cleanthe toolings and containers to avoid cross contamination of the resinwith conductive residues from the carbon veil.

The Wear Resistant Ceramic Layer

[0051] Continuing with FIGS. 1A-C and FIG. 5, a ceramic outer layer 10is used to provide a wear resistant jacket, as well as providing avisual cue for replacing the cover (when the ceramic cover is worn, thedifferent color underlying outer wall of the core may be visuallyobserved). Normal wear is due to mechanical abrasion and physicalcontact with the film or web, etching or stripping action of the corona,improper cleaning by scraping the roll with a hard edge, adversechemical reactions with improper cleaning solutions, brittleness andsurface cracks that develop due to high operating temperatures, andpeeling due to interaction with slip agents used in the extrusion offilms.

[0052] With the availability of a large selection of silica basedproducts designed for a multitude of ceramic coating applications, andoff the shelf ceramic coatings are available and are suitable. Keyelements to optimize include proper surface preparation of the outersurface of the core member, a high temperature binder 25 for priming thesurface to accept the ceramic coating, a ceramic powder coat suitablefor spraying 26 via spray gun 27, number of coats and proper airpressuresetting, thinning ratios and curing methods to avoid blistering andcracking. These key elements will ensure that the ceramic coatingadheres well to the composite tube and hold up under harsh industrialconditions without flaking or breaking off.

The Sealant Coat

[0053] Referring to FIGS. 1A-1C and FIG. 6, the function of the sealantcoat 11 is to encapsulate the ceramic coating 10 and make it moistureproof. Key elements in selecting a suitable sealant to use includecorona resistance, operating temperature in excess of 425 dF, extremelythin bond lines, low viscosity (below 1000 cps), and a durable finish.Following proper curing of the ceramic coating, the sealant can beapplied in a controlled room temperature environment. To ensure completeabsorption of the sealant by the ceramic coating, the composite covermust be placed in a negative pressure chamber 30 that is capable of 26″Hg or more. The negative pressure displaces any trapped air and moisturein the ceramic with the sealant. Several cycles of negative pressurefollowed by purging to a positive pressure will ensure thoroughabsorption, i.e., traditional Vacuum Pressure Impregnation (VPI)process.

The Mechanical Mounting System

[0054] Continuing with FIGS. 1A-1C and FIG. 7, a unique MechanicalMounting System (MMS) is provided for mounting the tube to the roller,axle, or other support. The MMS is configured to provide: (1) a sounddesign specifically addressing the issues concerning corona treatment,(2) positive and secure mount for the composite cover, (3) ease forreplacing the CCC in the field, (4) application robustness to includeboth the retrofit market and the OEM (Original Equipment Manufacturer)market. The design of the MMS as described in this invention is based onthe fundamentals for engineering functional corona treat rolls. Thedesign uses an expansion ring and a compression base.

Corona Treat Roll Fundamentals

[0055] The fundamentals for designing a successful treat roll areensuring a consistent and minimal total indicator runout (TIR);maintaining concentricity between the shaft, the roll and the cover; andensuring minimal deflection (commonly referred to as ‘whipping’) underhigh web load and high rotational speed. The MMS must meet theserequirements whether it is used to: (1) retrofit an existing roll, (2)design a new roll using the patented Winertia® Idler Roll Technology,and (3) design a new roll that is more economical to produce usingconventional thin-walled tubing.

The Expansion Ring

[0056] The composite makeup and tubular structure of the CCC requirespecial provisions for capturing it in place. Conventional engineeringpractice such as drilling holes in the cover and using fasteners couldlead to unnecessary sources for wear and tear; plus uneven pressurescould lead to distortion and out of round conditions. Furthermore, goodcontact between the conductive layer and the roll must be maintained forelectrical continuity. FIG. 7 shows an expansion ring design forcapturing the composite cover without any of the described compromises.

[0057] Referring to FIGS. 1A-1C and FIG. 7, as the name implies, theexpansion ring 35 comprises a disc body 36 forming an outer radialsurface 37, and an inner radial opening 38 having emanating therefromexpansion slots 39 and an expansion split 40. As shown, the expansionring is configured so that the outer radial surface 37 can be made toexpand 41 (and thereby increase its outer diameter) so that its outerdiameter may be made to engage the inner diameter 2 of the core member 8or tube T, causing the two parts to become attached by the force offriction. Some means for creating and maintaining radial lines of forcethat point away from the roll center is necessary for the Expansion Ringto establish concentricity with the roll shaft as will be more fullydisclosed herein.

The Compression Base

[0058] The working principle for a mounting base to complement theexpansion ring has to work in both a retrofit application and in a newdesign. First and foremost, the base must be designed with specialfeatures to ensure self-centering concentrically with the shaft.Secondly, engaging and positioning the base on the shaft must notrequire excessive pressure, or force. Thirdly, the method for securingthe base to the shaft must be noninvasive, i.e.; conventional setscrewsif used will dig into the shaft and permanently scar it. FIGS. 8A, 8Band 9A, 9B show a mounting compression base design for a dead-shaft rolland a design for a live-shaft roll, respectively. Both designs take intoaccount and satisfy all aforementioned issues.

[0059] As shown in FIGS. 1A-1C, FIG. 7, FIGS. 8A-8B, and FIGS. 9A-9B,the in use in a dead shaft roll incorporating a bearing, a bearingmember 44 is provided comprising a mounting hub 50 having a passageformed therethrough having an inner diameter 44, a body 51 having thebearings situated therein, and an outer diameter 43 forming anengagement surface for engaging a compression base 49. As shown, thebearing member 42 is mounted to a shaft 47 by passing the inner diameter44 about and along the shaft, so as to position 47′ the bearing memberat the desired location on along shaft.

[0060] Upon positioning of the bearing member at the desired location ofthe shaft, a compression base 49 is mounted about the outer diameter 43of the bearing member 42. The compression base 49 comprises a generallydisc configured body having a passage 53 formed there through having aninner diameter 52 which is configured to engage the outer diameter 43 ofthe bearing member 42. As shown, the compression base includes anexpansion split 54 as well as expansion slots 55 formed through the bodyto facilitate further opening or expansion of the inner passage 53 viamounting tools or the like for placement of the passage inner diameterabout the outer diameter 43 of the bearing member.

[0061] Upon placement of the compression base about the bearing member,expansion pressure from the mounting tools may be relieved so as toallow the compression base to retract 48 to its unexpanded, lesserdiameter configuration, so as to tighten about and securely engagebearing member 42. Alternatively the inner diameter 52 of thecompression base may be configured to slidingly engage the outerdiameter 43 of the bearing member, and upon the mounting and tighteningof the expansion ring about the outer diameter of the compression base(which would be positioned about the bearing member), as will bedescribed below, the compression base inner diameter would tighten aboutthe bearing member, so as to affix said compression base and expansionring in place about said bearing member.

[0062] As shown, the outer diameter 51 of the compression base 49 islaterally tapered from a more narrow diameter 45 to a wider diameter 46,to facilitate the expansion of an expansion ring thereabout as it ismounted about the outer diameter of the compression base, as will morefully be discussed infra.

[0063]FIGS. 9A and 9B illustrate the mounting of the compression base 49directly about a shaft 47″, bypassing the bearings as in FIG. 8 above,as would be in a live shaft roll. As shown, the compression base ismounted directly to the shaft in this instance, with the shaft passingthrough the inner diameter 52 of the base. Expansion slot and expansionslits, as discussed above, can be utilized to expand the unit formounting, or for facilitating contraction 48′ of the compression baseabout the shaft, either itself or in conjunction with the mounting ofthe expansion ring thereupon, as will be more fully discussed below.

System Design for the Retrofit Market

[0064] The present system can be made to retrofit existing third partyrollers as the best dielectric covered roll, plasma sprayed ceramic, isexpected to fail within five years. With the exception of rolls thatwere designed to be sleeved with silicone, all failed rolls (commonlycalled bonded dielectric) have to be sent back to the manufacturer forre-coating. It is not uncommon for users to put silicone sleeves ontheir failed bonded-dielectric rolls in order to avoid sending them backfor re-coating.

[0065] Corona treat rolls are either of the ‘dead’ shaft or ‘live’ shaftdesign with a dielectric cover made of silicone sleeve, bonded silicone,bonded epoxy, bonded hypalon, bonded rubber or plasma-sprayed ceramic. Adead shaft does not rotate with the roll while a live shaft and its rollturn together in one piece. As touched upon above, in use, rolls with adead shaft have the bearings supported by the non-rotating shaft, whichis bolted to the chassis and prevented from turning. Rolls with a liveshaft use ‘pillow block’ bearings that are supported by the chassis, andthe shaft goes through the race of the bearings.

Working Principle of the Retrofit System

[0066] By combining the Expansion Ring design to capture the compositecover and the Compression Base design to anchor it to the existing rollassembly, it is feasible to upgrade any previously covered roll to theFRCC system.

[0067]FIGS. 10A and 10B illustrate the expansion ring 35 mounted aboutthe compression base 49 (which base in turn is mounted about shaft 47′).As discussed above, the outer diameter 51 of the compression base 49 hasformed thereon a tapered surface 65 from narrow 45 to wide 46 about itsouter diameter; likewise, preferably, the expansion ring 35 may alsohave formed on its inner diameter 44 a complimentary tapered surface 56from narrow 57 to wide 58 to engage the outer diameter tapered surfaceof the compression base.

[0068] Continuing with FIGS. 10A, 10B, and 11A, 11B, the expansion ringhas first 59, second 60, and third 61, equidistantly spaced aperturesconfigured to align with like first 62, second 63, and third 64 threadedapertures formed in the compression base. In mounting the expansion ringto the base, the tapered 65 outer diameter of the compression base 49engages the tapered 56 expansion ring inner diameter in aligned fashion,and threaded fasteners or the like are passed through the expansion ringapertures 59, 60, 61 and into corresponding compression base apertures62, 63, 64, so that the expansion ring is drawn about toward 66 andabout the compression base, so that the tapered surfaces urge 67, 67′the expansion ring outer diameter 43 to increase so as to contact andengage 67 the inner wall 1 of tube T (in phantom). While the aboveexample illustrates the use of three apertures in each of the expansionring and base, respectively, it is noted that additional apertures 68may provide additional equalization of the pressure between theexpansion ring and the base.

[0069] The above illustration of the mounting of a single base andexpansion ring is to engage a first side of the tube, and theutilization of a second base and second expansion ring, mounted in like,opposing fashion for engaging the second end of the tube, would likewisehave to be performed for positive mounting of the tube to the shaft.

[0070] As shown, the shaft may carry an existing roller R, and the tubeT may be configured to envelope said roller, with the first 6 and secondends of the tube emanating from opposing sides of the roller, so as toallow the mounting of the compression base and expansion tube along theshaft on opposing ends of the roller, so as to support the opposing endsof the tube.

[0071] Of course, in such an application, the tube would be of a greaterlength than the roller which it is enveloping, so that the ends of thetube could emanate beyond the ends of the roller.

[0072] As indicated, the tapered inner diameter of the expansion ringeffectively provides two diameters which effect the outer diameter ofsaid ring, the first, unexpanded diameter which allows the outerdiameter to be placed within the inner diameter of the sleeve, and thesecond, expanded outer diameter, created as a result of the expansiondue to joining the compression base, which expanded diameter snugly andfirmly engages the inner diameter and inner wall of the tube T.

[0073] Further, the joining 71 of the tapered surfaces of the expansionring and compression base not only urge the expansion ring to expand 70,70′ to engage the inner diameter of tube T, but it also urges thecompression base to compress 73, 73′, resulting in a decrease of theinternal diameter 52 of the passage 53 formed in the compression base,causing the compression base to clamp down upon the shaft 47 further,and anchoring same in place along the shaft.

[0074] Thusly with an off-the shelf, live shaft roll, once thedielectric layer of the roll has been worn out, instead of replacing orrebuilding the roll, one may retrofit the roll with the sleeve andhardware mount of the present system to convert the old roll into asystem which allows the use of a field-replaceable sleeve or tube of thepresent invention.

[0075] In such a retrofit, the compression base may be positioned 74along the shaft at the desired location where it is to be mounted, inconjunction with the expansion ring, to engage an end of the tube.

[0076] Also, as discussed above, with a dead shaft roll, as shown inFIGS. 8A, 8B, the compression base 49 is mounted to a bearing member 42(as opposed to directly to the shaft), with the expansion ring 35mounted to the compression base 49 as above, and caused to expand toengage the inner wall of the tube T as above via threaded fastenersurging the expansion ring and compression base's tapered surfaces towardone another, urging the outer diameter of the expansion base to engagethe inner diameter of the tube. Put another way, by tightening theinstallation screws in a gradual and orderly fashion, the taperedsurfaces are forced to slide tangentially in opposite directions. Thiscreates a double action that has an opposite effect on the ring and thebase. The ring expands inside the composite tube creating equal radiallines of force that cause the tube to grip the ring tighter and tighter.The reactive and radial lines of force on the base cause it to compressand grip tightly the OD of the shaft.

[0077] In tightening the expansion ring about the compression base,ideally, the base should start to compress first then force the ring toexpand. This will ensure that the base, the ring and the composite tubeestablish concentricity around the shaft, which is solid and guaranteedto be ‘round’. Moreover, by reacting against the solid shaft, equallydistributed radial lines of force are created.

[0078] Two sets of holes have been match drilled in the ring and thebase: the above discussed set for installation, as well as an additionalset to facilitate removal. As indicated, the apertures which are usedfor installation, have threads formed in the base. On the other hand,the holes that are used for removal have threads 73 formed in the ring,and no corresponding apertures in the base, so that threading the bolts75 through the threaded apertures in the ring urges 76 the ring and baseapart., as shown in FIG. 12.

[0079]FIG. 12 shows how the retrofit system can be quickly taken apartto allow fast and convenient field replacement of a worn out CCC. First,the installation screws are loosened and removed from the base. Two ofthe removed screws and are then threaded into the expansion ring. Bytightening the screws, the ring and the base are quickly forced apart.The force against the base is reacted by the end of the roll and pushesthe ring out from inside the composite cover. Again, this system doesnot necessitate the use of any force that could harm any part of thecover and roll assembly.

[0080] As iterated, the tube T must be manufactured to have a slip fitover the existing roll, which previously was covered by a dielectric ofsome kind. The slip fit is defined as not having to apply any force inorder to slide the tube over the outer diameter of the existing rollwhile allowing the two parts to remain in physical contact. The slip fitis vital in that it allows easy field installation and removal of thecomposite cover and lets the rigidity of the existing roll be carriedover to the tube. With regards to any additional deflection, the largestamount will be equal to the dimensional difference between the innerdiameter of the tube and the outer diameter of the roll being retrofit.

System Design for the OEM Market

[0081] Innovation and price traditionally drive the OEM market. Ifinnovation can bring to the market a better product and cut cost at thesame time, it will have the support of both the manufacturer and theuser. In the case of field-replaceable dielectric cover, the siliconesleeve is the most popular worldwide due to its replaceability. However,the silicone sleeve has little or no resistance to knife cuts, nicks andtear during normal handling. Price wise, it costs between $3.00 to$11.00 per inch depending on the diameter. Users typically pay $90.00 toas much as $1,100.00 apiece for their sleeves.

[0082] The system of the present invention delivers both innovation andlow manufacturing cost in one package. The composite tube T of thepresent invention is extremely resistant to knife cuts, nicks and tear.The same operating principle as described for the retrofit systemapplies in the design of a new roll for OEM applications. A totally newconcept in shown below by taking full advantage of a patented idler rolltechnology, which is trade marked under the name WINERTIA. Moreover, analternate concept is also shown for the conventional thin-walled tubing,which is used in the manufacturing of OEM treat rolls. Referring toFIGS. 13 and 14, an alternative embodiment of the present invention,which has been designed for retrofitting a WINERTIA type roll, providesan Adapter Ring designed to fit in the recess at the ends of theWinertia® tube with a very thin section extending out. As shown, theprior art WINERTIA roller 86 comprises a first 87 and second 87′ coremembers supporting opposite ends of inner 90 and outer 91 tubes, thecore members configured to provide air circulation through said innerand outer tubes for cooling and ventilating same.

[0083] The improvement of the present invention comprises a system forretrofitting the WINERTIA roller, providing a retrofit dielectricsleeve/tube over the outer tube 91, so as to envelope and extend beyondthe ends of the WINERTIA roller 86, said retrofit dielectric sleeve/tubeT fabricated in the manner discussed above in FIGS. 1A-1C, and 2-5, saidretrofit dielectric sleeve/tube T mounted via specially configuredadapter rings 79, 79′ at opposing ends of the roller, said adapter ringseach comprising a mounting flange 80 configured to engage the end 94 ofthe tube T (which extend beyond the ends of the WINERTIA roller), theadapter ring 79 further comprising a first outer diameter member 81having an outer diameter 95 configured to engage the inner diameter 97of that portion of the tube T emanating 99 beyond the WINERTIA roller,the adapter ring 79 further comprising adjacent to said first outerdiameter member 81 a second outer diameter member 82 having an outerdiameter 96 configured to engage the inner diameter 98 of the outer tube91 of the WINERTIA roller emanating 92 beyond the WINERTIA core member.In the present practice of the invention, the portion shown emanating 92beyond the WINERTIA core member must be machined from the ends of thetube to form same, so as to fit the adapter ring 79 therein.

[0084] Formed in the mounting flange 80 of the adapter ring 79 aremounting apertures 83, 83′ configured to align with thread inserts 84,84′ situated in the WINERTIA core members 87, 87′ both mountingapertures and respective thread inserts 84, 84′ configured to receivethreaded fasteners 85, 85′, respectively for fastening the adapter ringto the WINERTIA roller, while supporting the tube T in place about same.

[0085] It is imperative that the roll be fabricated first to includeshaft, recessed ends and thread inserts. It is iterated that first andsecond adapter rings are installed in opposing sides of the roll. Theassembly may have to be lathed for final machining followinginstallation of the tube T and adapter rings, so as to achieveconcentricity.

[0086] It is iterated that the tube T must be manufactured with aprecise ID to achieve a slip fit over the standard OD sizes ofcommercially available Winertia® tubing. The slip fit is defined as nothaving to apply any force in order to slide the tube T over the OD ofthe Winertia® tubing while allowing the two parts to remain in physicalcontact. The slip fit is vital in that it allows easy field installationand removal of the composite cover and lets the rigidity of theWinertia® tubing be carried over to the CCC. With regards to additionaldeflection, the largest amount will be equal to the dimensionaldifference between the ID of the CCC and the OD of the Winertia® tubing.

FRCR/Conventional Tubing Roll Design

[0087] The technology for building treat rolls using a conventional(steel or aluminum) thin-walled tubing instead of the Winertia® tubinghas some significant advantages such as the abundant and low cost DOM(Drawn Over Mandrel) tubing; the availability of matured businessescompeting for a well-known product thus lowering the cost; and theoverall familiarity with the manufacturing process. The invention of thepresent system is easily and readily adaptable to the design andmanufacturing of corona treat rolls using DOM tubing. FIG. 15A shows aroll design for OEM applications.

[0088]FIG. 15A shows a typically constructed live-shaft roll on top todepict how readily this conventional design can be retrofitted for thesystem of the present invention, which is shown in FIG. 15B. As depictedin FIGS. 15A and 15B, the conventional live-shaft roll consists of first100 and second 100′ plugs engaging the inner diameter 103 of the DOMtubing 102, the first and second plugs engaging two short shafts 101,101′, respectively (or a single long shaft). The plugs and the shaftsare designed to have an interference fit with the tubing to allow themto be heat shrunk permanently in place.

[0089] To convert the conventional roll design to the present system,first 104 and second 104′ Adapter Rings are configured to attach torespective end plugs 100, 100′. The plugs are recessed a few inchesinside the roll to minimize any tendency by the roll to ‘whip’(technically defined as deflection) at high web load and high rotationalspeed. The recess also allows room for the new adapter rings to engagethe end plugs, as well as the inner diameter of the OEM tube.

[0090] Like the adapter rings of FIG. 14, the adapter ring of thepresent application has a mounting flange 105 to engage the ends 108,108′ of the tube T, a first OD member 106 having an outer diameter toengage the a inner diameter of the tube T, and may further include asecond OD member 103 having an outer diameter to engage the innerdiameter of the DOM tubing 102 emanating past plugs 100, 100′, the tubeT of the present invention comprising the composite dielectric tube Tdiscussed in FIGS. 1A-1C, and 2-5, said tube T having an inner diameterto allow it to slip over while contacting the outer diameter of the DOMtubing 102, and a length to emanate beyond both ends of the DOM tubing.

[0091] The Adapter Rings are similar in design to the one used for theWinertia® tubing OEM design discussed above. One adapter ring can bepermanently fastened or welded to the roll. Another variation of theadapter ring is match drilled to the plug with two sets of holes forinstalling and removing the composite cover.

[0092] The machining process is similar as well for the criticaldimensions OD1, OD2, OD3 and F as shown in FIG. 14. It is important tonote that the cost saving is in the machining time, which can be cut inhalf since the finish of the roll is no longer critical. Specifically,the composite cover eliminates the need to have a fine finish on the DOMtubing for the purpose of covering it with a bonded dielectric.Moreover, the adapter rings can be produced in mass by casting tominimize the additional cost of adding them to the final OEM treat rollproducts.

[0093] In summary, the method of servicing a corona roller having ashaft and a roller body having an outer diameter, a length, and firstand second ends, may be summarized as follows::

[0094] a. providing a sleeve of dielectric material, said sleeve havingan inner diameter sufficient to enable said sleeve to slide over theouter diameter of the cylindrical body of the roller, while allowing theinner wall of said sleeve to engage the outer diameter of saidcylindrical body;

[0095] b. slidingly positioning said sleeve over said roller body suchthat said length of said sleeve envelopes the cylindrical body of theroller, while allowing first and second ends of said sleeve to extendbeyond the first and second ends of said cylindrical body of saidroller, so as to provide first and second free ends of said sleeveemanating beyond the first and second ends of the cylindrical body ofsaid roller;

[0096] c. applying a first mechanical mount to said first free end ofsaid sleeve emanating beyond the first end of the cylindrical body ofsaid roller so as to anchor said first end of said sleeve to saidroller;

[0097] d. applying a second mechanical mount to second free end of saidsleeve emanating beyond the second end of the cylindrical body of saidroller so as to anchor said second end of said sleeve to said roller;

[0098] e. allowing said sleeve to function as a dielectric roller, whileprotecting the cylindrical body of said roller.

[0099] The invention embodiments herein described are done so in detailfor exemplary purposes only, and may be subject to many differentvariations in design, structure, application and operation methodology.Thus, the detailed disclosures therein should be interpreted in anillustrative, exemplary manner, and not in a limited sense.

[0100] Elements of the Invention

[0101] Title: Field-Replaceable Composite Roll System for CoronaTreatment

[0102] Inventor: Pham T Tube 1 inner wall  2 inner diameter  3 outerwall  4 outer diameter  5 thickness  6 first  7 second ends  8 coremember  9 conductive layer 10 ceramic layer 11 sealant coat 12 passage13 light source 14 opaque area 15 paint 16 spray head 17 hose 18 19 20carbon veil strip 21 mandril 22 tape anchor 23 motor 24 continuous layer25 binder 26 spraying 27 spray gun 28 29 30 vacuum chamber 31 coremember 32 sealant 33 vacuum pump 34 35 expansion ring 36 disc body 37outer radial surface 38 inner radial opening 39 expansion slots 40expansion split 41 expand 42 bearing member 43 outer diameter 44 innerdiameter 45 taper narrow 46 wide 47 shaft ^( 47′) applied 48 retract 49compression base 50 mounting hub 50 body 51 outer diameter - compression52 inner diameter - compress 53 passage 54 expansion slit - compres 55expansion slots compress 56 expansion ring taper 57 narrow 58 wide 59expansion ring threaded aperture 60 ″ 61 ″ 62 compression base apertures63 ″ 64 ″ 65 compression base taper 66 toward 67 engage 68 aperture 6970 expansion R Roller 71 joining 72 of the expansion base 73 threads inring 74 positioned 75 threaded fasteners 76 urges 77 78 79 Adapter Ring80 Mounting flange 81 First OD member 82 Second OD member 83 Mountingapertures 84 Thread inserts 85 Threaded fasteners 86 Winertia roller 87Winertia core member 88 sleeve 89 shaft 90 inner tube 91 outer tube 92emanates 93 iD 94 end 95 OD 96 OD 97 ID 98 ID 99 Emanating 100 Plugs 101Shafts 102 DOM tubing 103 ID 104 Adapter rings 105 Flange 106 First ODmember 107 Second OD member 108 Ends of tube T

I claim: 1). A corona electrode roller system for use with a rollerhaving a cylindrical body having first and second ends, a length and anouter diameter, and a shaft longitudinally emanating therefrom,comprising: a sleeve of dielectric material having a conductive innerwall, said sleeve having an inner diameter sufficient to enable saidsleeve to slide over the outer diameter of the cylindrical body of theroller, while allowing the conductive inner wall of said sleeve toengage the outer diameter of said cylindrical body, said sleeve having alength to envelope the cylindrical body of the roller, while allowingsaid first and second ends of said sleeve to extend beyond the first andsecond ends of said cylindrical body of said roller when said sleeve isslipped over said cylindrical body of said roller, so as to providefirst and second free ends of said sleeve emanating beyond the first andsecond ends of the cylindrical body of said roller; first and secondmechanical mounts for engaging said first and second free ends of saidsleeve, and anchoring said first and second free ends to the roller,each of said first and second mechanical mounts further comprising: acompression base having a central passage formed therethrough forreceiving the shaft of the roller, said compression base having an outerdiameter which is laterally tapered from a lesser outer diameter to agreater outer diameter; a generally disc shaped expansion ring, saidexpansion ring having formed therethrough a passage having an innerdiameter formed to engage the outer diameter of said compression base;wherein tightening the engagement of said expansion ring to saidcompression base increases the outer diameter of said expansion ring toengage the inner diameter of said sleeve, while decreasing the innerdiameter of the passage formed in said compression base, to tighten saidcompression base about said shaft. 2) The corona electrode roller systemof claim 1, wherein said tube is formed of a conductive layer of carbonveil strip having laminated thereon a layer of filament winding boundtogether by resin. 3) The corona electrode system of claim 2, whereinthe outer diameter of said sleeve has applied thereon a ceramic outercoating. 4) The coronal electrode system of claim 3, wherein saidceramic outer coating is a different color than the underlying filamentwinding and resin, so that the wearing through of said ceramic outercoating results in an observable color change. 5) The corona electrodesystem of claim 4, wherein there is applied to said ceramic outercoating a clear sealant. 6) The corona electrode system of claim 5,wherein the inner diameter of said passage formed through said expansionring is tapered from a lesser inner diameter to a greater innerdiameter, so as to facilitate compression of said compression base, aswell as expansion of said outer diameter of said expansion ring, upontightening of said compression base to said expansion ring. 7) Themethod of servicing a corona roller having a shaft and a roller bodyhaving an outer diameter, a length, and first and second ends,comprising the steps of: a. providing a sleeve of dielectric material,said sleeve having an inner diameter sufficient to enable said sleeve toslide over the outer diameter of the cylindrical body of the roller,while allowing the inner wall of said sleeve to engage the outerdiameter of said cylindrical body; b. slidingly positioning said sleeveover said roller body such that said length of said sleeve envelopes thecylindrical body of the roller, while allowing first and second ends ofsaid sleeve to extend beyond the first and second ends of saidcylindrical body of said roller, so as to provide first and second freeends of said sleeve emanating beyond the first and second ends of thecylindrical body of said roller; c. applying a first mechanical mount tosaid first free end of said sleeve emanating beyond the first end of thecylindrical body of said roller so as to anchor said first end of saidsleeve to said roller; d. applying a second mechanical mount to secondfree end of said sleeve emanating beyond the second end of thecylindrical body of said roller so as to anchor said second end of saidsleeve to said roller; e. allowing said sleeve to function as adielectric roller, while protecting the cylindrical body of said roller.8. The method of claim 7, wherein said first and second mechanicalmounts each comprise: a compression base having a central passage formedtherethrough for receiving the shaft of the roller, said compressionbase having an outer diameter which is laterally tapered from a lesserouter diameter to a greater outer diameter; a generally disc shapedexpansion ring, said expansion ring having formed therethrough a passagehaving an inner diameter formed to engage the outer diameter of saidcompression base; and wherein in step “c” and “d” the step of applyingsaid first and second mechanical mounts further comprises the steps of:i. placing a first compression base about said shaft in the vicinity ofthe first end of said sleeve, and applying and tightening a firstexpansion ring to said to said first compression base so as to increasethe outer diameter of said expansion ring to engage the inner diameterof said first end of said sleeve, while decreasing the inner diameter ofthe passage formed in said first compression base, so as to tighten saidcompression base about said shaft and anchor said first end of saidsleeve in place; and ii. placing a second compression base about saidshaft in the vicinity of the second end of said sleeve, and applying andtightening a second expansion ring to said to said second compressionbase so as to increase the outer diameter of said expansion ring toengage the inner diameter of said second end of said sleeve, whiledecreasing the inner diameter of the passage formed in said secondcompression base, so as to tighten said compression base about saidshaft and anchor said second end of said sleeve in place 9) The methodof claim 7, wherein said first and second mechanical mounts eachcomprise: an adapter ring comprising a mounting flange to engage the endof the sleeve, a first OD member having an outer diameter configured toengage the inner diameter of said sleeve, said first OD member laterallyemanating from said adapter ring, and a second OD member having a secondouter diameter configured to engage the inner diameter of saidcylindrical body of said roller; and wherein in step “c” and “d” thestep of applying said first and second mechanical mounts furthercomprises the steps of: i. placing a first adapter ring about said shaftin the vicinity of said first end of said sleeve, engaging said first ODmember to said inner diameter of said sleeve, engaging said second ODmember to said inner diameter of said cylindrical body of aid roller,and fastening said adapter ring to said roller. ii. placing a secondadapter ring about said shaft in the vicinity of said second end of saidsleeve, engaging said first OD member to said inner diameter of saidsleeve, engaging said second OD member to said inner diameter of saidcylindrical body of said roller, and fastening said adapter ring to saidroller. 10) The method of claim 7, wherein said first and secondmechanical mounts each comprise: an adapter ring comprising a mountingflange to engage the end of the sleeve, a first OD member having anouter diameter configured to engage the inner diameter of said sleeve,said first OD member laterally emanating from said adapter ring, saidmounting flange further having formed therein fastener apertures forreceiving a fastener configured to engage and retain said adapter ringto an end of said cylindrical body of said; and wherein in step “c” and“d” the step of applying said first and second mechanical mounts furthercomprises the steps of: i. placing a first adapter ring about said shaftin the vicinity of said first end of said sleeve, engaging said first ODmember to said inner diameter of said sleeve, and fastening saidmounting flange to said cylindrical body of said roller via saidfastener apertures formed in said mounting flange. ii. placing a secondadapter ring about said shaft in the vicinity of said first end of saidsleeve, engaging said first OD member to said inner diameter of saidsleeve, and fastening said mounting flange to said cylindrical body ofsaid roller via said fastener apertures formed in said mounting flange.11). A corona electrode roller system for use with a roller having acylindrical body having first and second ends, a length and an outerdiameter, and a shaft longitudinally emanating therefrom, comprising: asleeve of dielectric material having a conductive inner wall, saidsleeve having an inner diameter sufficient to enable said sleeve toslide over the outer diameter of the cylindrical body of the roller,while allowing the conductive inner wall of said sleeve to engage theouter diameter of said cylindrical body, said sleeve having a length toenvelope the cylindrical body of the roller, while allowing said firstand second ends of said sleeve to extend beyond the first and secondends of said cylindrical body of said roller when said sleeve is slippedover said cylindrical body of said roller, so as to provide first andsecond free ends of said sleeve emanating beyond the first and secondends of the cylindrical body of said roller; first and second mechanicalmounts for engaging said first and second free ends of said sleeve, andanchoring said first and second free ends to the roller, each of saidfirst and second mechanical mounts further comprising: fastening meansfor fastening said adapter ring to said first or second end of saidcylindrical body of said roller. 12) The corona electrode roller systemof claim 11, wherein said tube is formed of a conductive layer of carbonveil strip having laminated thereon a layer of filament winding boundtogether by resin. 13) The corona electrode system of claim 12, whereinthe outer diameter of said sleeve has applied thereon a ceramic outercoating. 14) The coronal electrode system of claim 13, wherein saidceramic outer coating is a different color than the underlying filamentwinding and resin, so that the wearing through of said ceramic outercoating results in an observable color change. 15) The corona electrodesystem of claim 14, wherein there is applied to said ceramic outercoating a clear sealant. 16) The corona electrode system of claim 15,wherein the inner diameter of said passage formed through said expansionring is tapered from a lesser inner diameter to a greater innerdiameter, so as to facilitate compression of said compression base, aswell as expansion of said outer diameter of said expansion ring, upontightening of said compression base to said expansion ring. 17) Thecorona electrode system of claim 16, wherein said first and secondmechanical mounts each further comprise: an adapter ring comprising amounting flange to engage the end of the sleeve, a first OD memberhaving an outer diameter configured to engage the inner diameter of saidsleeve, said first OD member laterally emanating from said adapter ring,and a second OD member having a second outer diameter configured toengage the inner diameter of said cylindrical body of said roller. 18.The corona electrode system of claim 17, wherein said first and secondmechanical mounts each further comprise: an adapter ring comprising amounting flange to engage the end of the sleeve, a first OD memberhaving an outer diameter configured to engage the inner diameter of saidsleeve, said first OD member laterally emanating from said adapter ring,said mounting flange further having formed therein fastener aperturesfor receiving a fastener configured to engage and retain said adapterring to an end of said cylindrical body of said roller.